Resin mortar composition for construction and floor operating method using the same

ABSTRACT

The present invention relates to a resin mortar composition, which has excellent flowing property, storage property, excellent self-leveling property when constructed, and excellent abrasion resistance, surface scratch resistance, crack resistance and durability after construction, which can be easily constructed and easily control curing time, and is economical. According to the present invention, there are provided a resin mortar composition for construction, which comprises, on the basis of solid content, a) 100 parts by weight of room temperature curable organic liquid phase resin; b) 10 to 200 parts by weight of glass bead, c) 10 to 400 parts by weight of glass powder, and d) 0.1 to 50 parts by weight of glass fiber, and a method for constructing a floor that has beautiful surface and does not show crack using the same.

BACKGROUND OF THE INVENTION

(a) Field of the Invention

The present invention relates to a resin mortar composition that hasexcellent flowing property, storage property, self-leveling propertywhen constructed, and excellent abrasion resistance, surface scratchresistance, crack resistance and durability after constructed, can beeasily constructed and easily control curing time, and is economical,and a method for constructing a floor that has beautiful surface anddoes not show crack using the same.

(b) Description of the Related Art

Conventional resin mortar comprises a liquid phase resin and a fillersuch as quartz sand, and it is constructed on a floor by mixing it witha curing agent in an appropriate mixing ratio while agitating, mixingquarts sand therewith, coating the mixture on a construction surfacewith a specific thickness, decorating it using a decoration apparatus,and repeatedly constructing and curing additional resin until a uniformcoating forms, in a construction field. Generally, a resin is mixed withfillers such as quartz sand, the quartz sand absorbs the resin hence aviscosity largely increases making it difficult to be uniformlydispersed, and even if uniformly dispersed, phase separation of theresin and quartz sand easily occurs. Therefore, a resin mortar should bemixed in a construction field. Since such a mixing in a constructionfield should be conducted manually with small amount at a time, treatedamount is limited and a lot of hands and equipment are required in orderto construct a large area, making it inefficient and increasingconstruction cost.

In addition, in the case of a resin mortar containing quartz sand asfillers, since the quartz sand absorbs the resin, the absolute amount ofthe filler functioning for bonding is insufficient and resin isprevented from remaining on the surface of quartz sand, which decreasesstrength and causes damages.

In addition, in order to facilitate construction, the amount of fillerfor resin should be limited, and if the amount of filer increases,operability is not good and construction is difficult. And, in case afiller covered with a small amount of resin is contained, it is directlyexposed as time passes by, making it exposed to various impacts. Inaddition, after construction, if quartz sand used as a filler is exposedor an upper coating film is damaged by various causes during usage, thesurface of quartz sand is contaminated to make the surface appearanceinferior, and since cleaning of quartz sand is impossible because of itsproperty, contaminants are absorbed into the pores of quartz sand orinside of it, which causes offensive odor and bacterial growth, and ifwater or oil is introduced for a long period, surface separation of aresin and a filler may be caused.

Meanwhile, a lining operation, which is a kind of conventionalself-leveling for building, uses talc or calcium carbonate, etc. as afiller hence it has good flowing property. However, since it requirescomparatively expensive resin, it is uneconomical. And, afterconstruction, hardness, compression strength and adhesion strength arelow and thus adhesion, durability, scratch resistance, etc. areinferior. In addition, inhalation property for water, oil, etc. andcontamination resistance are identical to general resin mortar, and ifwater or oil remains on its surface, it becomes very slippery to causesafety accident.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a resin mortarcomposition having excellent flowing property, storage property andself-leveling property when constructed.

It is another object of the present invention to provide a resin mortarcomposition having excellent abrasion resistance, surface scratchresistance, crack resistance and durability after constructed.

It is another object of the present invention to provide a resin mortarcomposition that can be easily constructed, can easily control curingtime and is economical.

It is another object of the present invention to provide a method forconstructing a floor that has beautiful surface and does not show crackusing the resin mortar composition.

In order to achieve these objects, the present invention provides aresin mortar composition for construction, which comprises:

-   -   on the basis of solid contents,    -   a) 100 parts by weight of a room temperature curable organic        liquid phase resin;    -   b) 100 to 200 parts by weight of glass beads;    -   c) 10 to 400 parts by weight of glass powder; and    -   d) 0.1 to 50 parts by weight of glass fiber.

The present invention also provides a method for constructing a resinmortar, which comprises the steps of:

a) coating a resin mortar comprising:

-   -   i) 100 parts by weight of a room temperature curable organic        liquid phase resin;    -   ii) 10 to 200 parts by weight of glass beads;    -   iii) 10 to 400 parts by weight of glass powder; and    -   iv) 1 to 50 parts by weight of glass fiber on a floor;

b) spraying glass beads on the floor on which the resin mortar is coatedto remove bubbles produced in the coated resin mortar; and

c) curing the resin mortar floor from which bubbles are removed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view showing one example of resin mortar ofthe present invention constructed on a bottom surface of cementconcrete.

FIG. 2 is a photograph showing abrasion resistance results of curedresin mortar of the present invention.

Reference numeral 1 denotes resin, 2 filler, 2 a glass beads, 2 b glasspowder, 2 c glass fiber, 3 a cement bottom surface, 10 a sample beforeabrasion resistance test, and 20 a sample after abrasion resistancetest.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present inventors have discovered that if glass beads are containedin a resin mortar as fillers, even if a large amount is contained, avolume filling property and compatibility are superior and flowingproperty of resin mortar significantly increases, and completed thepresent invention.

The present invention blends a room temperature curable organic liquidphase resin such as epoxy based, acryl based, urethane based, alkydbased, polyester based, or polyvinylchloride based resin, etc. withglass beads, glass powder and milled glass fiber as fillers whileagitating, thereby providing a resin mortar composition that hassuperior flowing property, storage property and self-leveling propertywhen constructed, and superior abrasion resistance, surface scratchresistance, crack resistance, weather resistance and durability afterconstructed, and that can be easily constructed, can easily controlcuring time, and is economical. Such a resin mortar does not generatevoids because of complicated bonding of small glass powder or milledglass fiber that fill voids between glass beads of various sizes, hassuperior impact resistance because of buffering effects due to pressuredispersion of glass beads against external impact, and has superiorflowing property because viscosity does not increase hence remarkablyimproving construction operability.

As the room temperature curable organic liquid phase resin used in theresin mortar of the present invention, conventionally used epoxy based,acryl based, urethane based, alkyd based, polyester based, orpolyvinylchloride based resins can be used. As the epoxy based resin, asolvent or non-solvent type diglycidyl type or triglycidyl type epoxyresin that has molecular weight of 350 to 3,000 MW is preferable. As theacryl based resin, a solvent type acryl urethane that has methacrylicacid derivatives as main ingredients, an aqueous acrylhydrosol, anemulsion non-solvent type acryl silane, or a UV curable acryl ispreferable. As the alkyd based resin, paint shaped alkyd resin that ismodified with polyacidic base and polyhydric alcohol ester compounds ispreferable, and alkyd resins modified with rosin, phenol, epoxy, vinylstyrene monomer, isocyanate or silicon can be used. As the polyvinylchloride based resin, a PVC plastic sol liquid phase resin ispreferable.

These resins function as a binder of the resin mortar, and confer acidresistance and alkali resistance. And, if necessary, they can be curedby adding a curing agent, and a cure-promoting agent can be used inorder to control curing speed. The curing agent and cure-promoting agentare selected according to the kinds and amounts of the resins, and theamount thereof can be determined considering the use of the constructedfloor and construction conditions.

If the content of the room temperature curable liquid phase resin is toolow, its function as a binder is insufficient, and if the content is toohigh, the content of a filler decreases and thus hardness, strength andother physical properties as a floor are inferior. Therefore, the resinand the filler should be blended with the above-mentioned ratio.

Since the glass beads used in the present invention do not have resinabsorbing property differently from silica conventionally used as afiller, even if a large amount is used, mixing and dispersion is goodand volume filling effect is superior. Particularly, it gives highflowing property to a resin mortar due to the spherical effects of glassbeads, it also gives self-leveling property, and it provides superiorstorage property such that a resin composition comprising a resin andfillers is well mixed by a simple agitation even after stored for a longperiod. In addition, since the glass beads have higher hardness thansilica, they increase surface hardness after a resin mortar is cured togive abrasion resistance, and they provide a surface property of scratchresistance and surface contamination preventing effect. And, when animpact is applied to a cured resin mortar, the glass beads dispersepressure to give high impact resistance because they have spherical orsimilar shapes. And, the glass beads make an expensive resin mortareconomical due to high volume filling properties.

In addition, the glass beads give flame-retarding property to a resinmortar because they are inflammable, and they inhibit generation ofstatic electricity to prevent surface contamination of a constructedresin mortar. And, since the glass beads are made of glasses, they givetransparent or white color to a resin mortar, and they give variouscolors or various patterns such as granite pattern together with otherpigments or color chips. And, they can use a large amount of sunlight orirradiated light from a separate lighting to cause diffused reflectionthereby decreasing gloss produced from a resin.

As the glass beads used in the present invention, those of spherical,oval or similar shapes can be used, and those having various sizedistribution or those having a specific size can be used. However, thesize of the glass bead is preferably selected according to the use ofconstructed floor and constructed thickness. Preferably, the sized ofglass beads are 200 meshes to 3 mm. If particles of less than 200 meshesare used, volume filling property and impact resistance may deteriorate.If particles of more than 3 mm are used, dispersion may be deterioratedor a resin mortar may be protruded because a resin mortar is coated witha thickness of approximately 0.3 to 10 mm. And, appropriate color can begiven to a resin mortar using appropriate colored glass beads.

The glass beads are preferably contained in an amount of 10 to 200 partsby weight, based on 100 parts by weight of resin solid content, morepreferably in an amount of 50 to 100 parts by weight. If the content isless than 10 parts by weight, flowing property of a resin mortardecreases, and strength and hardness may decrease after cured. And, ifthe content is more than 200 parts by weight, strength decreases andthey may be missed after cured. It is preferable to use increased amountof glass beads for a floor to which much load is given, and to usedecreased amount for a thin resin mortar construction.

The glass powder used in the resin mortar is mixed with a resin toincrease a viscosity thereby preventing precipitation or sedimentationof fillers such as glass beads, fills voids between the glass beads toincrease impact resistance and tensile force, and inhibits expansion andcontraction. And, since the glass powder has hardness of 6 to 7, itenforces surface hardness of resin mortar after cured to increasescratch resistance and give slip-preventing function.

As the glass powder, those of various shapes and sizes can be used. Theglass powder is obtained by pulverizing a common glass and itscomposition is not specifically limited so long as it is compatible witha resin such as A, C, E alkali resistant glass powder compositions, etc.The particle size of the glass powder is preferably 10 μm to 1 mm, andaverage particle diameter is preferably smaller than those of the glassbeads in order to fill voids between the glass beads. If glass powder ofless than 10 μm is used, viscosity increases, and if glass powder ofmore than 1 mm is used, void-filling is not good hence strength maydecrease and contraction and expansion may increase.

The glass powder is preferably contained in an amount of 10 to 400 partsby weight, based on 100 parts by weight of resin solid content, and morepreferably in an amount of 50 to 100 parts by weight. If the content isless than 10 parts by weight, the viscosity of the resin mortardecrease, and contraction and expansion increase after cured. And, ifthe content is more than 400 parts by weight, viscosity increases toomuch, resin content decreases to lower strength, and glass beads may bemissed after resin mortar is cured. The glass powder can be contained ina large amount because it does not absorb resin. It is preferable to usedecreased amount of glass powder in order to lower viscosity in caseconstructed under low temperature conditions, to use increased amountfor a floor to which much load is applied, and to use decreased amountfor a thin resin mortar construction.

The glass fiber used in the present invention exists in a resin toincrease tensile force of cured resin mortar and prevent cracks. As theglass fiber, long glass fiber of E glass composition is preferable, andalkali resistance fiber can be used. And, a chopped fiber that isprepared by cutting a glass fiber with a fiber diameter of 10 to 20 μmto uniform stand lengths, or a milled fiber prepared by milling to aaverage fiber lengths can be used. The chopped fiber is preferably thosecut to fiber length of 2 to 12 mm, and the milled fiber is preferablythose having average fiber length of 100 to 300 μm. The milled fiber ispreferable in terms of tensile force enforcement and dispersion, and thecombination of the chopped fiber and milled fiber can be used.

The glass fiber is preferably contained in an amount of 1 to 50 parts byweight, based on 100 parts by weight of resin solid content. If thecontent is less than 1 part by weight, tensile force of the cured resinmortar decreases, cracks are generated, and contraction and expansionincrease. And, if the content is more than 50 parts by weight, mixingand dispersion is difficult.

In order to control construction operability of the resin mortar, asolvent such as benzyl alcohol can be added to control viscosity. Thesolvent is selected according to a kind of room temperature curableorganic liquid phase resin, and it is preferably added in an amount of 1to 1000 parts by weight based on 100 parts by weight of the resin solidcontent. The viscosity is suitably 5000 to 10000 cps in case a resinmortar is coated on a floor, and 15000 to 20000 cps in case coated on awall.

In order to give color to the resin mortar, colored glass bead can beused, or a pigment or color chip can be added. The pigment and the colorchip is preferably added in an amount of 0.1 to 20 parts by weight,based on 100 parts by weight of resin solid content in terms of mixingand dispersion, and blending stability, and the pigments is morepreferably added in an amount of 0.1 to 5 parts by weight. As the colorchip, basic color chips such as white, black or other colors containedin artificial granite, etc., and as the resin used in the color chip,polymethylmethacryalte or polyester is preferable in terms ofcompatibility with the resin. And, natural granite pattern can be easilyobtained by introducing various color chips of various sizes and colors.

The resin mortar of the present invention can be used for floors, wallfinishing, waterproof agent, floor surface repairing agent, loadrepairing agent, etc., and it has superior abrasion resistance andadhesion to constructed body, and thus it can finish a floor surfacebeautifully even if constructed with a thin thickness of 0.3 to 5 mm ona cement concrete such as a commercial building, a factory floor, aparking lot floor, etc., or on a steel such as ships or automobiles.

The method for constructing a resin mortar on a floor surface will nowbe explained.

The conventional resin mortar using silica as filler has insufficientsilica flowing property, and thus it cannot be stored and used aftermixing due to precipitation and tangle. However, in the resin mortar ofthe present invention, although primary precipitation forms duringstorage due to self gravity of glass bead fillers, since precipitatesmove because of superior flowing property if a direction of storagecontainer is changed, the precipitates are not solidified and dispersedagain, hence the resin mortar of the present invention can be stored andused for a long period. Therefore, construction can be completed byadding in place resin additives such as a curing agent, curing promoter,etc. to a resin mortar prepared in the factory, and then immediatelycoating it a floor surface, removing bubbles generated from the resin,and curing it. And, since the resin mortar of the present invention hassuperior flowing property and thus self-leveling property, coating iscompleted simply by pouring the resin mortar onto a floor and flatteningthe surface of the resin mortar using simple equipment such as a rake,etc.

If the resin mortar of the present invention is coated on a wide floor,bubbles form from the resin due to hidden bubbles in concrete and resinproperties, which may remain as pockmarks on a resin mortar surface andcause floor contamination and cracks. Therefore, in order to remove suchbubbles, glass beads are sprayed together with compressed air before thecoated resin mortar is cured. The spraying of the glass beads breaksbubbles to completely remove bubbles. And, the glass beads sprayed ontoa surface are deposited into the resin mortar or remain on the surfacedue to superior compatibility and flowing property, thereby obtainingsmooth surface again. The spraying is conducted by spouting the glassbeads on the upper part of the coated resin mortar together with airunder pressure of 1 to 10 kgf/cm² using a spray equipment connected to acompressor. The amount of the sprayed glass beads are preferably set to10 to 100 g/m². Therefore, the upper part of the resin mortar containsglass beads in a higher density than the lower part.

Before the resin mortar of the present invention is coated on a floorsurface, common primer coating can be conducted on a floor surfaceaccording to the conditions of floor surface. The primer coatingmaterial is selected according to floor surface and resin material, andfor a cement floor surface, epoxy-based, acryl-based, or urethane-basedemulsion primer is preferable.

FIG. 1 is a cross-sectional view showing one example wherein the resinmortar of the present invention is constructed on a cement concretefloor surface. In the resin (1), glass beads (2 a), glass powder (2 b)and glass fiber (2 c) are dispersed as fillers (2) to form a cured body.And, as the glass beads (2 a), those of various sizes can be usedtogether, and a part of them can be protruded on the surface of thecured body.

If the resin mortar of the present invention is constructed on a floor,it can be firmly adhered to most floors regardless of floor material,and after cured, it can be cleanly maintained as indoor paper-coveredfloor because of its superior contamination resistance, and it canfinish floor for heavy walking because of its superior hardness andstrength. And, the construction method of the present invention canobtain a floor that has beautiful surface and does not generate cracks.

The present invention will be explained in detail with reference to thefollowing Examples. However, these are only to illustrate the presentinvention and the present invention is not limited to them.

EXAMPLES Example 1

(Preparation of Resin Mortar)

1 kg of epoxy liquid phase resin (Kuk-do Chemicals YD-128) and 20 g ofbenzyl alcohol were mixed, and 1000 g of glass beads with particlediameter distribution of 0.3 to 0.5 mm (Jisan Industry), 1200 g of glasspowder with average particle diameter of 200 meshes and specific gravityof 2.54 (Kumyoong Industry Co. Ltd.), 50 g of milled glass fiber withaverage fiber thickness of 13.5 μm, and average fiber length of 300 μm(Kumyoong Industry Co. Ltd. MF300), and 150 g of green pigment weremixed therewith in a common mixer to prepare a resin mortar.

The prepared resin mortar was green, and its specific gravity was 1.3,600 gloss was 85%, and flowing property was 50 cm as result of slumptest. The resin mortar is put in a steel cam, and stored at roomtemperature for 12 months, and then it is opened. As results, it wasobserved that fillers are partially precipitated but they are notsolidified, and when shaking the can, the fillers are uniformlydispersed again, and slump test result showed 50 cm.

Example 2

(Floor Construction of Resin Mortar)

After cleaning common cement concrete floor surface, an epoxy-basedemulsion primer (Carboline Korea, KOP coating 340 gold primer) wascoated and naturally cured. After one hour, the resin mortar prepared inthe Example 1 was mixed with 400 g of amine type curing agent (KukdoChemical G-715) and 4 g of amine type cure-promoter (German HuntzmanCompany, AEP), and then it was poured onto the floor surface and thesurface was flattened to a thickness of 5 mm using a rake. Then, thesame glass beads as used in the Example 1 were sprayed onto the upperpart of the resin mortar in an amount of 10 g/m² under pressure of 2kgf/cm² using a paint spray connected to a compressor, thereby removingbubbles. The resin mortar was cured at room temperature for 8 hours toobtain a final floor surface wherein resin mortar is constructed to athickness of 5 mm on a cement concrete.

The surface of the obtained green floor surface was smooth and 60° glosswas 85%.

The other physical properties of the floor surface were described in thefollowing Table 1. TABLE 1 Results In water adhesion strength (kgf/cm²)32.6 Wet adhesion strength (kgf/cm²) 37.8 Dry adhesion strength(kgf/cm²) 97.5 Tensile force (kgf/cm²) 200 Bending strength (kgf/cm²)510 Compression strength (kgf/cm²) 860 Hardness (shore-D) 89 Shearadhesion strength (kgf/cm²) 87

The physical properties were measured according to JIS-K6911.

In addition, the same resin mortar mixture as the above except excludingcure-promoter was coated on a steel plated to a thickness of 30 μm, andwas completely cured at 20° C. for 1 day, and then physical propertieswere measured according to JIS-K6911. The results were described in thefollowing Table 2. TABLE 2 Results drying time (hr, at 25° C.) Within 8hrs. Pencil hardness (H) 1˜2 Cross cut test (RO/100) 100/100 Bendingtest (φ 3 mm, 180) Pass Adhesive test (number/10) 10/10 Erichsen test(mm) 5.7

In addition, the same mixture as the above except excluding a pigmentand a cure-promoter was coated on a release paper to prepare a sample of10×10×120 mm, and was completely cured at 20° C. for 1 hour, and thenchemical resistance was evaluated. The sample was immersed in variouschemical solutions as shown in the following Table 3 for 1 month, andthen taken out to measure weight decrease. TABLE 3 Weight decrease rate(wt %) Boiling water 0.0001 NaOH aqueous solution of 40 wt %concentration −0.0035 HCl aqueous solution of 36 wt % concentration1.065 H₂SO₄ aqueous solution of 50 wt % concentration 0.188 Acetic acidaqueous solution of 10 wt % −0.035 concentration seawater solution 0.362Xylene 0.068 Ethanol 0.645 K₂Cr₂O₅ of 10 wt % concentration −0.068

In addition, the same mixture as the above except excluding a pigmentand a cure-promoter was coated on a release paper to prepare a sphericalsample with a thickness of 5 mm (φ 100), and then was completely curedat 20° C. for 1 day. Then, abrasion resistance was tested by 20,000times of repetitive frictions using a brush. As results, the coating ofthe resin mortar maintained without break and loss, and weight decreasewas 0.015 wt %. The appearance of the sample was shown in FIG. 2.Reference numeral 10 indicates a sample before conducting a test, andreference numeral 20 a sample after test.

Example 3

The resin mortar was prepared with the same composition as in Example 1,except that 30 g of combination color chip of white, black, blue and redwas mixed instead of a pigment, and the prepared resin mortar was coatedon a cement concrete floor by the same method as in Example 2 and curedto obtain a floor with natural granite pattern. The physical propertiesof the floor were identical with those in Example 2.

The resin mortar of the present invention uses glass beads havingsuperior flowing property and high hardness as a filler and thus hassuperior self-leveling property when constructed, and superior abrasionresistance, scratch resistance, crack resistance and durability afterconstructed, and it can be easily constructed and easily control curingtime. The construction method using the composition can obtain a floorthat has beautiful surface and does not generate cracks.

1. A resin mortar composition for construction comprising: on the basisof solid content, a) 10 parts by weight of a room temperature curableorganic liquid phase resin; b) 10 to 200 parts by weight of glass beads;c) 10 to 400 parts by weight of glass powder; and d) 0.1 to 50 parts byweight of glass fiber.
 2. The resin mortar composition according toclaim 1 further comprising e) 0.1 to 20 parts by weight of a pigment ora color chip.
 3. The resin mortar composition according to claim 1further comprising f) 1 to 100 parts by weight of a solvent.
 4. Theresin mortar composition according to claim 1, wherein the a) roomtemperature curable organic liquid phase resin is selected from thegroup consisting of an epoxy-based resin, an acryl-based resin, anurethane-based resin, an alkyd-based resin, a polyester-based resin anda polyvinylchloride-based resin.
 5. The resin mortar compositionaccording to claim 1, wherein the b) glass beads have particle sizes of200 meshes to 3 mm.
 6. The resin mortar composition according to claim1, wherein the c) glass powder has particle size of 10 μm to 1 mm. 7.The resin mortar composition according to claim 1, wherein the d) glassfiber is chopped fiber that is prepared by cutting glass long fiber ofE-glass composition to a length of 2 to 12 mm, or a milled fiber that isprepared by milling to a length of 100 to 300 μm.
 8. A method forconstructing a resin mortar on a floor, which comprises the steps of: a)coating a resin mortar comprising: on the basis of solid content, i) 10parts by weight of a room temperature curable organic liquid phaseresin; ii) 10 to 200 parts by weight of glass beads; iii) 10 to 400parts by weight of glass powder; and iv) 0.1 to 50 parts by weight ofglass fiber on a floor; b) spraying glass beads on the floor that iscoated with the resin mortar to remove bubbles produced in the coatedresin mortar; and c) curing the resin mortar floor from which bubblesare removed.
 9. The method according to claim 8, wherein a primercoating is conducted on a floor before the step a).
 10. The methodaccording to claim 8, wherein the resin mortar of the step a) furthercomprises v) 0.1 to 20 parts by weight of a pigment or a color chip. 11.The method according to claim 8, wherein in the step b), glass beads aresprayed in an amount of 1 to 100 g/m² together with air having pressureof 1 to 10 kgf/cm².